Method and apparatus for making body heating and cooling garments

ABSTRACT

A method and apparatus for making garments that can cool or heat the wearer of the garment. In one embodiment, the method comprises the steps of providing a pattern board having a channel configuration formed thereon that defines at least one channel circuit, disposing a first fusible fabric over the channel configuration of the pattern board, disposing a length of tubing over the channel configuration and depressing the tubing into the channels, disposing a second fabric over the tubing and first fusible fabric to form a first laminate assembly, and applying heat and pressure to the laminate assembly to form a laminate garment structure.

BACKGROUND OF THE INVENTION

[0001] The invention described herein may be manufactured and used bythe U.S. Government for Governmental purposes without the payment of anyroyalty thereon.

[0002] 1. Field of the Invention

[0003] The present invention relates to a method for fabricating bodyheating and cooling garments.

[0004] 2. Description of Prior Art

[0005] Military personnel, astronauts and other persons operating inextreme temperature environments typically require a heating or coolinggarment. Typically, such garments are air and vapor permeable andcomprise synthetic tubing that carries cooling or heating fluid medium.The tubing is in close body contact so as to effect transfer of the heator cold to the wearer of the garment.

[0006] The heating or cooling garment can be configured into differentshapes and sizes. For example, many heating or cooling garments aretypically configured as vests. The garment utilizes tubing that isattached to a liner. Since pressures within the tubing can reach 100p.s.i. (pounds/square inch), the mating of the tubing to its substratemust be fluid pressure-insensitive. The liner is then attached to afabric which forms the outer portion of the garment. These garments arepreferably stretchable and flexible to conform to the shape of the bodyof the individual. Furthermore, these garments provide mobility for armsand legs, and retain the tubing close to the body for more efficienttransfer of heat or cold. The flexibility produces relatively lessdamage to the tubing during garment flexure and substantially reducesthe likelihood of punctures or tears to the garment. Moreover, there isa requirement that these garments be relatively lightweight and easy toclean.

[0007] One conventional method for fabricating these garments involvessewing the tubing to a substrate or liner which is sufficiently porousto allow internal vapors to escape as well as to provide for airpermeability. However, a significant problem with sewing the tubing isreferred to as “needle holing”. Needle holing requires that every inchof the tubing be sewn to the porous substrate. Such a techniquesignificantly increases the risk of puncturing the tubing during thesewing process. Furthermore, the threads themselves provide a majorirritant when the tubes are pressed into contact with the body.Additionally, the sewing method is slow and expensive. Automated sewingtechniques are not viable options due to the difficulty of achievingregistration of the tubing with predetermined patterns.

[0008] Another disadvantage of stitching or sewing arises when chemicalprotective clothing is being fabricated. In such a situation, stitchingthe tubing to any substrate results in needle holes that permit unwantedchemicals to move from one side of the garment to the other. Oneconventional technique used in an attempt to eliminate this problem withsewing or stitching is to fabricate the heating/cooling garments with abladder sealed at its edges wherein the cooling fluid is containedwithin the bladder. However, while bladder-type garments do in factconduct heat away from the body or conduct heat to the body, theresulting garment is non-breathable, non-stretchable and non-flexibledue to the two-coated fabrics which are joined together by heat.Furthermore, flexibility of the garment is impeded when a relativelylarge volume of liquid is captured in the garment. Additionally, onlyconduction can be used to remove heat since a bladder-type garment posesan impermeable barrier against natural perspiration. Therefore, thebladder-type cooling garment completely eliminates the possibility ofevaporative or convective cooling. A further disadvantage of thebladder-type garments is that the edges of the bladder deteriorate whensubjected to pressures higher than 30 psi.

[0009] There are other conventional methods for attach tubing to a lineror substrate. One such method involves brushing or rolling adhesivesonto liners to adhere the tubing to liners. However, all lining porosityis destroyed when the adhesive is massively applied across thesubstrate.

[0010] Another conventional technique is to use adhesive tape to securethe tubing to the liner. Specifically, the adhesive tape contacts theliner to either side of the tube along its length. This technique isexceedingly difficult to implement due to the fact that when the tubingis formed around small radius corners, the overlying strip of tape hasto be notched in order to follow the tubing around the comers.Furthermore, tape impedes the ability of the garment to stretch and alsodegrades garment permeability. Additionally, tape does not alwayssufficiently adhere the tubing to the liner.

[0011] What is needed is a new and improved method for making such aheating and cooling garment that solves the problems mentioned in theforegoing discussion that are associated with conventional methods andalso provides all the desirable characteristics such as flexibility andpermeability. Furthermore, such a new and improved method should resultin a relatively lower per-unit manufacturing cost of the garment.

SUMMARY OF THE INVENTION

[0012] In one aspect, the present invention is directed to a method formaking garments that can cool or heat the wearer of the garment. In oneembodiment, the method comprises the steps of the method comprising thesteps of providing a pattern board having a channel configuration formedthereon that defines at least on channel circuit, disposing a firstfusible fabric over the channel configuration of the pattern board,disposing a length of tubing over the channel configuration anddepressing the tubing into the channels, disposing a second fabric overthe tubing and first fusible fabric to form a first laminate assembly,and applying heat and pressure to the laminate assembly to form alaminate garment structure.

[0013] In a related aspect, the present invention is directed to amethod for making a garment that can cool or heat a wearer of thegarment, the method comprising steps of providing a pattern board havingfirst side, a second side and a channel configuration having channelsthat define at least one circuit, providing a length of tubing having anexterior surface, applying a heat-activated adhesive upon the exteriorsurface of the tubing, depressing the tubing into the channels, placinga first fabric layer upon the tubing, ironing the first fabric toactivate the adhesive so as to adhere the tubing to the first fabric,lifting the first fabric with the tubing adhered thereto from thepattern board, placing the first fabric with the tubing adhere theretoon a substantially flat surface with the tubing side facing up, applyinga second adhesive to the tubing and first fabric layer, applying asecond fabric over the tubing and first fabric layer such that thesecond fabric contacts the adhesive wherein the fabrics and the tubingforming a laminate assembly, applying heat and pressure to the laminateassembly so as to activate the second adhesive thereby forming alaminate garment structure.

[0014] In yet a further aspect, the present invention is directed to amethod for making a garment for heating and cooling the wearer of thegarment, the method comprising the steps of providing a pattern boardcomprising a first side having a channel configuration formed thereinthat defines at least one channel circuit and a plurality ofsubstantially flat portions adjacent the channel configuration. Thepattern board further comprises a second side opposite the first side.The method further comprises the steps of disposing a first layer offlexible material over first side of the pattern board, disposing anadhesive film over the first layer of flexible material, disposing asecond layer of flexible material over the adhesive film wherein thelayers of flexible material and adhesive film form a laminate assembly,and applying heat and pressure to the laminate assembly so as toactivate the adhesive film and fuse together the portions of the layersof flexible material that correspond to the substantially flat portionsof the first side of the pattern board.

[0015] In another aspect, the present invention is directed to a patternboard comprising a first side that defines a channel configurationhaving channels that define at least one circuit wherein each channelhas a bottom surface, a second side opposite the first side, and atleast one turn-about member attached to the bottom surface of eachchannel

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The features of the invention are believed to be novel and theelements characteristic of the invention are set forth withparticularity in the appended claims. The invention itself, both as toorganization and method of operation, may best be understood byreference to the detailed description which follows taken in conjunctionwith the accompanying drawings in which:

[0017]FIG. 1 is a diagrammatic representation of a heating or coolingsuit or garment having tubes through which a heating or cooling mediumis pumped;

[0018]FIG. 2 is a top view of fusible fabric used by the method of thepresent invention;

[0019]FIG. 3 is a top plan view of a pattern board of the presentinvention;

[0020]FIG. 4 is a top plan view of an enlarged portion of the patternboard shown in FIG. 3.

[0021]FIG. 5 is the top plan view of FIG. 4 showing the placement oftubing with channels of the pattern board.

[0022]FIG. 6 is a top plan view of an alternate embodiment of thepattern board of the present invention.

[0023]FIG. 7 is an exploded view of a laminate assembly produced byintermediate steps of one embodiment of the method of the presentinvention.

[0024]FIG. 8 is a cross-sectional view of a laminate garment structureproduced by one embodiment of the method of the present invention.

[0025]FIG. 9 is top plan view of a further embodiment of the patternboard of the present invention

DETAILED DESCRIPTION

[0026] Referring to FIG. 1, wearer 10 is wearing heating/cooling garmentor suit 12 of the present invention. Garment 12 includes heating orcooling tubing 14 dispersed throughout garment 12. Tubing 14 is suppliedwith heating or cooling fluids via an umbilical connection line 16 whichis connected to a heating/cooling unit 18. Garment 12 is extremelyflexible, durable, and both air and vapor permeable so as to permitcooling via not only the conduction of the tubing adjacent to thewearer's, but also by the escape of vapor from the body to ambient (i.e.cooling via convection).

[0027] Referring to FIG. 2, garment 12 further comprises fusible fabric20 in an open weave or open lattice structure which provides therequired air and vapor permeability. Such a fusible fabric is describedin commonly owned U.S. Pat. No. 5,320,164, the disclosure of which isincorporated herein by reference. Fabric 20 includes a number ofpatterned dots 22 that adhere to the intersections between the wovenstrands 24. Such a configuration is also described in the aforementionedU.S. Pat. No. 5,320,164. In another embodiment, fabric 20 is not woven.In one embodiment, fabric 20 is fabricated from high pile fleece.

[0028] Referring to FIGS. 3 and 4, there is shown pattern board 30 inaccordance with the present invention. Pattern board 30 has top surface31 and an opposite side (not shown). Pattern board 30 can be fabricatedfrom a variety of materials. In one embodiment, pattern board 30 isfabricated from a phenolic heat-resistant plastic. Other suitablematerials can be used. Pattern board 30 comprises a plurality ofchannels 32. Each channel 32 has a bottom surface 34 and a plurality ofturn-about members 36 a-z that extend upward from bottom surface 34. Itis to be understood that channels 32 can have more or less than theactual number of turn-about members 36 a-z shown. Each member 36 a-z hasa pair of curved ends 38 and 40. Curved channels 42 are formed betweeneach member 36. Channel 32 comprises channel portion 44 that extends onone side of each member 36 a-z. Channel 32 further comprises channelportion 46 that extends on the other side of the each member 36 a-e.Channel 44 includes portion 44 a and through which tubing (not shown)can enter or exit pattern board 30. Similarly, channel 46 includesportion 46 a through which tubing (not shown) can enter or exit patternboard 30. Referring to FIG. 4, channels 42, 44 and 46 are all sized forreceiving tubing (not shown) used to fabricate a heating or coolinggarment. It is to be understood that each channel 32 can be configuredto provide channels 42, 44 and 46 of varying sizes in order toaccommodate tubing of various diameters.

[0029] Referring to FIG. 5, turn-about members 36 allow serpentinetubing configurations of different sizes to be fabricated. The size ofthe tubing configuration depends upon the size of the garment. Tubing 50can be wrapped around turn-about member 36 c of each channel 32 for arelatively small garment, or around turn-about member 36 a for arelatively large garment. In one embodiment, tubing 50 is perforated toform an air vest.

[0030] Referring to FIG. 3, the channel portions 44 and 46 that sharethe same piece of tubing 50 comprise a channel circuit. Thus, referringto FIG. 3, pattern board 30 comprises six channel circuits 52, 54, 56,58, 60, and 62. Although FIG. 3, shows just six circuits, it is to beunderstood that pattern board 30 can be configured to have less than sixcircuits or more than six circuits. As shown in FIG. 3, pattern board 30is configured to have a generic serpentine channel design that can beused to make garments of varying sizes. It is to be understood that thechannel configuration of pattern board 30 is just one example and thatother configurations can be used. Furthermore, the channel configurationcan be modified to provide channel portions 44 a and 46 a.

[0031] Referring to FIG. 6, there is shown an alternate pattern board 70in accordance with the present invention. Pattern board 70 generallycomprises a substantially flat surface 72 and a specific serpentinechannel configuration 73 that has lower portion 74 and upper portion 76.Pattern board 70 is suitable for fabricating a heating/cooling vest.Upper portion 76 defines one circuit and corresponds to the upperportion of the vest that covers the upper torso, chest and lowershoulder area of a wearer. Lower portion 74 defines another circuit andcorresponds to the lower portion of the vest that covers the abdomen,lower torso portion, and the hip area of the wearer. Upper portion 76comprises channel 82. Channel 82 is sized for receiving a specific sizetubing (not shown). Channel 82 has portions 82 a and 82 b through whichthe tubing (not shown) can enter or exit pattern board 70. Similarly,lower portion 74 comprises channel 80. Channel 80 is sized to receive aspecific size tubing (not shown). Channel 80 has portions 80 a and 80 bthrough which the tubing (not shown) enters and exits pattern board 70.Portions 80 a, 80 b, 82 a and 82 b allows the tubing to be connected tosources of heating or cooling medium. Pattern board 70 does not utilizeturn-about members such as members 36 described in the foregoingdescription. It is to be understood that the serpentine channelconfiguration is just one example and that other configurations can beused. Furthermore, the serpentine channel configuration can be modifiedto provide portions 80 a, 80 b, 82 a and 82 b at different locations.

[0032] The particular channel pattern in pattern boards 30 and 70depends upon the type of heating/cooling garment that is to bemanufactured, e.g. vest, suit, etc.

[0033] Each step of one embodiment of the method of the presentinvention is described in the ensuing description wherein reference ismade to FIGS. 2, 3, 4 and 7.

[0034] a) The first step is to provide a pattern board that has thedesired channel configuration. For purposes of describing the steps ofthe method of the present invention, reference will be made to patternboard 30 shown in FIGS. 3, 4 and 7.

[0035] b) The next step entails selecting the number of circuits ofpattern board 30 that are to be utilized for making the desired garment.

[0036] c) Next, a first layer of fabric 90 is disposed over the patternboard 30 specifically covering the selected circuits. In one embodiment,fabric 90 is configured in the same manner fusible fabric 20 describedin the foregoing description and shown in FIG. 2.

[0037] d) Next, tubing 92 having the appropriate diameter is disposedover fabric 90 and depressed into channel portions 44 and 46 (see FIG.5) such that portions of fabric 90 are also disposed with channelportions 44 and 46 and are intermediate tubing 92 and pattern board 30.Tubing 92 is simply fitted into channel portions 44 and 46 withoutapplying adhesives.

[0038] e) The next step of the method of the present invention comprisesdisposing second fabric 94 over tubing 92 to form a laminate assembly.Fabric 94 can be either fusible or non-fusible.

[0039] f) Next, laminate assembly is inserted into a press wherein heatand pressure are applied to the laminate assembly in order to melt theadhesive dots of fabric 90 so as to fuse fabric 90 to tubing 92 and toportions of fabric 94 that surround tubing 92 to form a laminate garmentstructure 100 shown in FIG. 8. The application of heat and pressure witha press is described in the aforementioned U.S. Pat. No.5,320,164.

[0040] g) Next, the laminate garment structure 100 is removed from thepress and allowed to cure (i.e. cool).

[0041] h) Next, any excess fabric is removed from laminated garmentstructure 100 so as to enable the garment to take its desired shape,e.g. vest. suit, etc. Fabrics 90 and 100 determine the air/vaporporosity of the resulting garment.

[0042] In an alternate embodiment, fabric 94 is first disposed overpattern board 30. Tubing 92 is then disposed over fabric 94 anddepressed within the channel portions (i.e. portions 44 and 46) of theselected circuits. Next, fusible fabric 90 is then disposed over the topof tubing 92. The resulting laminate assembly is then placed in thepress for the application of heat and pressure as described above.

[0043] In a further embodiment, fabric 90 does not contain any adhesivedots. Instead, a first layer of adhesive film is disposed over fabric90. Next, tubing 92 is disposed over the adhesive film and is depressedinto the channel portions (i.e. portions 44 and 46 of channel 32) of theselected circuits. A second adhesive film is then disposed over tubing92. Fabric 94 is then disposed over the second adhesive film. Theresulting laminate assembly is then placed in the press for theapplication of heat and pressure as described above.

[0044] In yet a further embodiment, a chemical protective-type fabric(not shown) is first disposed over pattern board 30. Tubing 92 is thendisposed over the chemical protective-type fabric and depressed withinthe selected channel portions (i.e. channel portions 44 and 46). Next,fusible fabric 20 is then disposed over the top of tubing 92. Theresulting laminate assembly is then placed in a press for theapplication of heat and pressure as described in the foregoingdescription. In one embodiment, the chemical protective-type layer isSYMPATEX™.

[0045] In another embodiment, the method of the present inventioncomprises the following steps:

[0046] a) applying a heat-activated adhesive upon the exterior surfaceof the tubing;

[0047] b) placing tubing 92 into the selected channel portions (i.e.portions 44 and 46) of pattern board 30;

[0048] c) placing a first fabric layer upon tubing 92 and removing anywrinkles in the first fabric;

[0049] d) ironing the first fabric to activate the adhesive and form abi-component laminate assembly;

[0050] e) lifting the bi-component laminate assembly from the patternboard and place the bi-component laminate assembly on a flat surfacewith the tubing side facing up;

[0051] f) applying a second adhesive to tubing 92 and the first fabriclayer;

[0052] g) applying a second fabric over the tubing and first fabriclayer such that the second fabric contacts the adhesive to form atri-component structure;

[0053] h) placing the tri-component structure in a press and applyingheat and pressure to the tri-component structure so as to activate thesecond adhesive; and

[0054] i) removing the tri-component structure from the press andallowing the tri-component structure to cure.

[0055] In a preferred embodiment, the ironing step is accomplished witha conventional consumer-type iron. In a preferred embodiment, the steamsetting of the iron is not utilized. In one embodiment, the secondadhesive is a moisture-cure type adhesive that is sprayed on the tubingand first fabric. In a preferred embodiment, the second adhesive is ofthe type that does not penetrate through the surface of the first andsecond fabrics. In a preferred embodiment, the second adhesive drieswithout stickiness. In one embodiment, the application of heat andpressure is accomplished via a press as described in the foregoingdescription.

[0056] In another embodiment, the method of the present invention isdirected to making a garment for heating or cooling a wearer wherein thegarment contains no tubing but does contain a plurality of interiorchannels therein for receiving heating or cooling medium or wires, e.g.fiber optic cables. Such an embodiment comprises the following steps:

[0057] a) providing pattern board 200 having a first side 202, a secondside (not shown) and channel configuration 204 formed in the first side202 that defines a circuit. As shown in FIG. 9, channel configuration204 comprises serpentine channel 206. Channel 206 includes portions 206a and 206 b that provide for the formation of inlet or outlets in thefinished garment to allow the introduction of heating or fluid medium,wires, fiber optic cable, etc. The portions of first side 202 that arenot part of channel 206 are indicated by numeral 208 and, in oneembodiment, are substantially flat

[0058] b) disposing a first layer of flexible material over first sideof the pattern board;

[0059] c) disposing an adhesive film over the first layer of flexiblematerial;

[0060] d) disposing a second layer of flexible material over theadhesive film wherein the layers of flexible material and adhesive filmform a laminate assembly;

[0061] e) applying heat and pressure to the laminate assembly so as toactivate the adhesive film and fuse together the portions of the layersof flexible material that correspond to portions 208 of the patternboard thereby forming a laminate garment structure having interiorfluid-tight and vapor-tight channels between the layers of flexiblematerial; and

[0062] f) curing the laminate garment structure.

[0063] In one embodiment, each of the layers of flexible materialcomprises coated aluminum foil. In another embodiment, each of thelayers of flexible material is a film-based fusible material. In afurther embodiment, each of the layers of flexible material is atextile-based fabric. In one embodiment, the application of heat andpressure is accomplished by using a press as described in the ensuingdescription.

[0064] Once the basic laminate garment structure is fabricated by any ofthe methods described above, excess fabric is trimmed away. Once a pairof laminate garment structures are fabricated, the garment structuresand be secured together to form the front and a garment, i.e. vest, witha front side and a back side of the garment. In one embodiment, shoulderstraps are used to attach the upper portions of the garment structurestogether, and additional straps are used to attach the side portions ofthe garment structures together. However, any one of a variety methodsfor attaching the garment structures together can be used, e.g. snaps,hooks and fasteners, hook and loops, Velcro™, etc. thereby allowing onesize of the complete garment to fit wearers of many sizes. In apreferred embodiment, the garment structures are attached together so asto provide a close fit with the body of the wearer in order to maximizethe heating or cooling effect. In one embodiment, side pockets areincluded on the complete garment. In such an embodiment, the side pocketis configured as a stretch pocket of lycra fabric with a zipper closure.In one embodiment, the side pocket contains the tubing that feedsheating or cooling medium to the tubing interior of the garment orreceives heating or cooling medium from the tubing interior of thegarment.

[0065] As described in the foregoing description, the tubing serves as aconduit for a heating or cooling medium. A typical heating medium can behot or warm water, or heated gas (i.e. neon, fluorescent, etc.). Atypical cooling medium can be cool or cold water, or cold gases such asfreon or other refrigerants. Such heating or cooling mediums can beapplied via pumps or vacuum sources, or any other devices that createpressure. The tubing can also be used as a conduit for receiving wiresor fiber optic cables.

[0066] The adhesives described above are chosen from group comprisingpolyamids, polyesters, polyethylenes, polyvinyl chlorides, polyvinylacetates and polyvinyl acetate copolymers.

[0067] Thus, the present invention obviates many of the problems of theprior art and provides a stretchable, flexible, air permeable, vaporpermeable, and durable heating and cooling garment with a relativelylower weight and per-unit manufacturing cost. Furthermore, the resultingheating and cooling garment can be laundered and dry-cleaned.

[0068] The heating and cooling garment made in accordance with thepresent invention also has many applications, including, but notlimited, to garments for protection against chemical or biologicalagents and extreme temperature conditions. Thus, such garments can beused for military, sports and industrial purposes. Furthermore, thelaminated garment structures as described in the foregoing descriptioncan be used in other articles of manufacture as well, such as sleepingbags, tents, blankets, etc. Additionally, the laminated garmentstructures as described in the foregoing description can be used forentirely different purposes such as melting snow or ice from a surface,e.g. sidewalk, driveway, etc., or keeping items warm or hot, e.g. food,drinks, etc.

[0069] The principals, preferred embodiments and modes of operation ofthe present invention have been described in the foregoingspecification. The invention which is intended to be protected hereinshould not, however, be construed as limited to the particular formsdisclosed, as these are to be regarded as illustrative rather thanrestrictive. Variations in changes may be made by those skilled in theart without departing from the spirit of the invention. Accordingly, theforegoing detailed description should be considered exemplary in natureand not limited to the scope and spirit of the invention as set forth inthe attached claims.

Thus, having described the invention, what is claimed is:
 1. A methodfor making a garment that can heat or cool the wearer of the garment,the method comprising the steps of: a) providing a pattern board havinga channel configuration formed thereon that defines at least one channelcircuit; b) disposing a first fusible fabric over the channelconfiguration of the pattern board; c) disposing a length of tubing overthe channel configuration and depressing the tubing into the channels;d) disposing a second fabric over the tubing and first fusible fabric toform a first laminate assembly; and e) applying heat and pressure to thelaminate assembly to form a laminate garment structure.
 2. The methodaccording to claim 1 wherein the first fabric is air and vaporpermeable.
 3. The method according to claim 1 wherein the second fabricis air and vapor permeable.
 4. The method according to claim 1 whereinthe second fabric is fusible.
 5. The method according to claim 1 whereinthe channel configuration comprises a plurality of channels that definea plurality of channel circuits.
 6. The method according to claim Iwherein each channel has a bottom surface and at least one turn-aboutmember extending therefrom to allow the tubing to be depressed into onlya portion of the channel.
 7. The method according to claim 1 wherein thefirst fusible fabric contains a plurality of adhesive dots thereon thatare activated upon the application thereto of heat and pressure.
 8. Themethod according to claim 1 further including the step of curing thelaminate garment structure.
 9. The method according to claim 1 whereinthe applying step comprises the step of placing the laminate assemblyinto a press.
 10. The method according to claim 1 wherein the adhesivefilm is selected from the group of adhesives consisting of polyamids,polyesters, polyethylenes, polyvinyl chlorides, polyvinyl acetates andpolyvinyl acetate copolymers.
 11. The method according to claim 1further comprising the steps of: prior to disposing step (d), disposingan adhesive film over the tubing; and thereafter, disposing the secondfabric over the adhesive film.
 12. A method for making a garment forheating and cooling the wearer of the garment, the method comprising thesteps of: a) providing a pattern board comprising a first side thatincludes a channel configuration formed therein that defines at leastone channel circuit and a plurality of substantially flat portionsadjacent the channel configuration, and a second side opposite the firstside; b) disposing a first layer of flexible material over first side ofthe pattern board; c) disposing an adhesive film over the first layer offlexible material; d) disposing a second layer of flexible material overthe adhesive film wherein the layers of flexible material and adhesivefilm form a laminate assembly; and e) applying heat and pressure to thelaminate assembly so as to activate the adhesive film and fuse togetherthe portions of the layers of flexible material that correspond to thesubstantially flat portions of the first side of the pattern board. 13.The method according to claim 12 further including the step of curingthe laminate structure.
 14. The method according to claim 12 whereineach of the layers of flexible material comprises coated aluminum foil.15. The method according to claim 12 wherein each of the each of thelayers of flexible material comprises a film-based fusible material. 16.The method according to claim 12 wherein each of the layers of flexiblematerial is a textile-based fabric.
 17. A method for making a garmentthat can cool or heat a wearer of the garment, the method comprisingsteps of: a) providing a pattern board having a channel configurationhaving channels that define at least one channel circuit, the patternboard having a first side and a second side; b) providing a length oftubing having an exterior surface; a) applying a heat-activated adhesiveupon the exterior surface of the tubing; b) depressing the tubing intothe channels; c) placing a first fabric layer upon the tubing; d)ironing the first fabric to activate the adhesive so as to adhere thetubing to the first fabric; e) lifting the first fabric with the tubingadhered thereto from the pattern board; f) place the first fabric withthe tubing adhere thereto on a substantially flat surface with thetubing side facing up; g) applying a second adhesive to the tubing andfirst fabric layer; h) applying a second fabric over the tubing andfirst fabric layer such that the second fabric contacts the adhesive,the fabrics and the tubing forming a laminate assembly; and i) applyingheat and pressure to the laminate assembly so as to activate the secondadhesive thereby forming a laminate garment structure.
 18. The methodaccording to claim 17 wherein the ironing step further comprises thestep of removing any wrinkles in the first fabric.
 19. The methodaccording to claim 17 further comprising the steps of curing thelaminate garment structure.
 20. The method according to claim 17 whereinthe first fabric is a fusible fabric.
 21. The method according to claim17 wherein the second fabric is a fusible fabric.
 22. A garment madeaccording to the method of claim
 1. 23. A garment made according to themethod of claim
 12. 24. A garment made according to the method of claim17.
 25. A pattern board comprising: a first side defining a channelconfiguration having channels that define at least one channel circuit,each channel having a bottom surface; a second side opposite the firstside; and at least one turn-about member located within and extendingfrom the bottom surface of each channel.